Processes for recycling polystyrene waste

ABSTRACT

Processes for recycling polystyrene waste. The processes can comprise dissolving the polystyrene waste in ethylbenzene under conditions to obtain a polystyrene/ethylbenzene mixture, adding the polystyrene/ethylbenzene mixture to a hydrocarbon polystyrene non-solvent under conditions to obtain precipitated polystyrene and washing the precipitated polystyrene with additional portions of hydrocarbon polystyrene non-solvent under conditions to obtain twice-washed polystyrene. The twice-washed polystyrene can optionally be dried and formed into polystyrene pellets. There is also provided recycled polystyrene obtained from such processes for recycling polystyrene waste.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a 35 USC 371 national stage entry of PCT/CA2018/051472 filed on Nov. 20, 2018 and which claims priority to U.S. provisional application No. 62/588,805 filed on Nov. 20, 2017. These documents are hereby incorporated herein by reference in their entirety.

TECHNICAL FIELD

The present disclosure relates to a process for recycling polystyrene waste. For example, it relates to a process for recycling polystyrene waste comprising dissolving the polystyrene waste in a solvent such as ethylbenzene then precipitating and washing the polystyrene with a non-solvent.

BACKGROUND OF THE DISCLOSURE

Polystyrene waste, for example, the packaging from electronic products or furniture, food trays, commercial products and insulation can, for example, have environmental consequences.

For example, whether post-consumer or post-industrial, the majority of polystyrene waste is buried in landfills. For example, every year in Quebec more than 40,000 tons of polystyrene waste is buried. Further, more than 60,000 tons of new polystyrene is bought and consumed every year in Quebec.

Known processes for recycling polystyrene do not produce recycled polystyrene having the same properties as new polystyrene. For example, known methods of polystyrene do not prepare recycled polystyrene having a Melt Flow Index (MFI) which meets technical specifications for using the recycled polystyrene for the same uses as new polystyrene is used for. To compensate this loss of mechanical properties, the recycled polystyrene is blended with new polystyrene in a proportion that rarely can exceed 20%, even for the less stringent applications.

Most industrial polystyrene objects are not composed only of polystyrene; for example, they may contain chemicals added to a polymer to modify some physical, biological and/or chemical property. Examples of additives are: coloring agents, fillers, flame retardants, lubricants and plasticizers.

It would thus be desirable to be provided with a recycled polystyrene and a process for recycling polystyrene waste that would at least partially solve one of the problems mentioned or that would be an alternative to the known processes for recycling polystyrene waste.

SUMMARY OF THE DISCLOSURE

According to one aspect of the present disclosure, there is provided a process for recycling polystyrene waste, comprising:

-   -   dissolving the polystyrene waste in ethylbenzene under         conditions to obtain a polystyrene/ethylbenzene mixture;     -   adding the polystyrene/ethylbenzene mixture to a first portion         of hydrocarbon polystyrene non-solvent under conditions to         obtain precipitated polystyrene and a first portion of         hydrocarbon waste solution;     -   separating the precipitated polystyrene from the first portion         of hydrocarbon waste solution;     -   optionally repeating the dissolving, adding and separating;     -   washing the precipitated polystyrene with a second portion of         hydrocarbon polystyrene non-solvent under conditions to obtain         washed polystyrene and a second portion of hydrocarbon waste         solution;     -   separating the washed polystyrene from the second portion of         hydrocarbon waste solution;     -   washing the washed polystyrene with a third portion of         hydrocarbon polystyrene non-solvent under conditions to obtain         twice-washed polystyrene and a third portion of hydrocarbon         waste solution;     -   separating the twice-washed polystyrene from the third portion         of hydrocarbon waste solution; and     -   optionally drying the twice-washed polystyrene under conditions         to obtain dried polystyrene.

Therefore according to another aspect of the present disclosure, there is provided a process for recycling polystyrene waste, comprising:

-   -   dissolving the polystyrene waste in ethylbenzene under         conditions to obtain a polystyrene/ethylbenzene mixture;     -   contacting the polystyrene/ethylbenzene mixture with a first         portion of hydrocarbon polystyrene non-solvent under conditions         to obtain precipitated polystyrene and a first portion of         hydrocarbon waste solution;     -   separating the precipitated polystyrene from the first portion         of hydrocarbon waste solution;     -   optionally repeating the dissolving, adding, and separating;     -   washing the precipitated polystyrene with a second portion of         hydrocarbon polystyrene non-solvent under conditions to obtain         washed polystyrene and a second portion of hydrocarbon waste         solution;     -   separating the washed polystyrene from the second portion of         hydro-carbon waste solution;     -   washing the washed polystyrene with a third portion of         hydrocarbon polystyrene non-solvent under conditions to obtain         twice-washed polystyrene and a third portion of hydrocarbon         waste solution;     -   separating the twice-washed polystyrene from the third portion         of hydrocarbon waste solution; and     -   optionally drying the twice-washed polystyrene under conditions         to obtain dried polystyrene.

Therefore according to another aspect of the present disclosure, there is provided a process for recycling polystyrene waste, comprising:

-   -   dissolving the polystyrene waste in ethylbenzene under         conditions to obtain a polystyrene/ethylbenzene mixture;     -   adding the polystyrene/ethylbenzene mixture to a first portion         of hydrocarbon polystyrene non-solvent under conditions to         obtain precipitated polystyrene and a first portion of         hydrocarbon waste solution;     -   separating the precipitated polystyrene from the first portion         of hydrocarbon waste solution;     -   optionally repeating the dissolving, adding and separating;     -   washing the precipitated polystyrene with a second portion of         hydrocarbon polystyrene non-solvent under conditions to obtain         washed polystyrene and a second portion of hydrocarbon waste         solution;     -   separating the washed polystyrene from the second portion of         hydrocarbon waste solution;     -   washing the washed polystyrene with a third portion of         hydrocarbon polystyrene non-solvent under conditions to obtain         twice-washed polystyrene and a third portion of hydrocarbon         waste solution;     -   separating the twice-washed polystyrene from the third portion         of hydrocarbon waste solution;     -   removing surplus hydrocarbon waste solution by wringing and/or         compressing the twice-washed polystyrene; and     -   drying the twice-washed polystyrene under conditions to obtain         dried polystyrene.

Therefore according to another aspect of the present disclosure, there is provided a process for recycling polystyrene waste, comprising:

-   -   dissolving the polystyrene waste in ethylbenzene under         conditions to obtain a polystyrene/ethylbenzene mixture;     -   contacting the polystyrene/ethylbenzene mixture with a first         portion of hydrocarbon polystyrene non-solvent under conditions         to obtain precipitated polystyrene and a first portion of         hydrocarbon waste solution;     -   separating the precipitated polystyrene from the first portion         of hydrocarbon waste solution;     -   optionally repeating the dissolving, adding and separating;     -   washing the precipitated polystyrene with a second portion of         hydrocarbon polystyrene non-solvent under conditions to obtain         washed polystyrene and a second portion of hydrocarbon waste         solution;     -   separating the washed polystyrene from the second portion of         hydrocarbon waste solution;     -   washing the washed polystyrene with a third portion of         hydrocarbon polystyrene non-solvent under conditions to obtain         twice-washed polystyrene and a third portion of hydrocarbon         waste solution;     -   separating the twice-washed polystyrene from the third portion         of hydrocarbon waste solution;     -   removing surplus hydrocarbon waste solution by wringing and/or         compressing the twice-washed polystyrene; and     -   drying the twice-washed polystyrene under conditions to obtain         dried polystyrene.

Therefore according to another aspect of the present disclosure, there is provided a process for recycling polystyrene waste, comprising:

-   -   dissolving the polystyrene waste in ethylbenzene under         conditions to obtain a polystyrene/ethylbenzene mixture;     -   adding the polystyrene/ethylbenzene mixture to a first portion         of hydrocarbon polystyrene non-solvent under conditions to         obtain precipitated polystyrene and a first portion of         hydrocarbon waste solution;     -   cooling the precipitated polystyrene and the first portion of         hydrocarbon waste solution;     -   separating the precipitated polystyrene from the first portion         of hydrocarbon waste solution;     -   optionally repeating the dissolving, adding, cooling and         separating;     -   washing the precipitated polystyrene with a second portion of         hydrocarbon polystyrene non-solvent under conditions to obtain         washed polystyrene and a second portion of hydrocarbon waste         solution;     -   cooling the washed polystyrene and the second portion of         hydrocarbon waste solution;     -   separating the washed polystyrene from the second portion of         hydrocarbon waste solution;     -   washing the washed polystyrene with a third portion of         hydrocarbon polystyrene non-solvent under conditions to obtain         twice-washed polystyrene and a third portion of hydrocarbon         waste solution;     -   optionally cooling the twice-washed polystyrene and the third         portion of hydrocarbon waste solution;     -   separating the twice-washed polystyrene from the third portion         of hydrocarbon waste solution; and     -   optionally drying the twice-washed polystyrene under conditions         to obtain dried polystyrene.

Therefore according to another aspect of the present disclosure, there is provided a process for recycling polystyrene waste, comprising:

-   -   dissolving the polystyrene waste in ethylbenzene under         conditions to obtain a polystyrene/ethylbenzene mixture;     -   contacting the polystyrene/ethylbenzene mixture with a first         portion of hydrocarbon polystyrene non-solvent under conditions         to obtain precipitated polystyrene and a first portion of         hydrocarbon waste solution;     -   cooling the precipitated polystyrene and the first portion of         hydrocarbon waste solution;     -   separating the precipitated polystyrene from the first portion         of hydrocarbon waste solution;     -   optionally repeating the dissolving, adding, cooling and         separating;     -   washing the precipitated polystyrene with a second portion of         hydrocarbon polystyrene non-solvent under conditions to obtain         washed polystyrene and a second portion of hydrocarbon waste         solution;     -   cooling the washed polystyrene and the second portion of         hydrocarbon waste solution;     -   separating the washed polystyrene from the second portion of         hydrocarbon waste solution;     -   washing the washed polystyrene with a third portion of         hydrocarbon polystyrene non-solvent under conditions to obtain         twice-washed polystyrene and a third portion of hydrocarbon         waste solution;     -   optionally cooling the twice-washed polystyrene and the third         portion of hydrocarbon waste solution;     -   separating the twice-washed polystyrene from the third portion         of hydrocarbon waste solution; and     -   optionally drying the twice-washed polystyrene under conditions         to obtain dried polystyrene.

The present disclosure also includes recycled polystyrene prepared according to a process for recycling polystyrene waste of the present disclosure.

Polystyrene waste such as expanded polystyrene waste is typically bulky but light whereas the polystyrene/ethylbenzene mixture typically has a higher density which may therefore cost less to transport. Accordingly, the processes of the present disclosure may, for example, save on transportation costs if, for example, the polystyrene/ethylbenzene mixture is obtained at a first location and the process further comprises transporting the polystyrene/ethylbenzene mixture to a second location wherein subsequent steps in the process are carried out.

The process for recycling polystyrene waste of the present disclosure may, for example allow removal of most additives (for example, chemicals added to a polymer to modify some physical, biological and/or chemical property) and can produce recycled polystyrene having properties very close to that of new polystyrene. The recycled polystyrene prepared from the processes of the present disclosure may, for example, be suitable for use for the same uses as new polystyrene such as for the preparation of new polystyrene articles. For example, the recycled polystyrene prepared from the processes of the present disclosure may, for example, have an MFI within a useful range for such uses.

It was found that the recycled polystyrenes of the present disclosure and the processes for obtaining same were quite useful. In fact, it was found that such recycled polymers and processes allowed for providing recycled polystyrene having a very low content of additives (fillers and/or lubricants). That also leads to recycled polystyrene having a very low content in ash. For example, when applying these processes to white expanded or extruded polystyrene, the final product is very clear and transparent to light transmission. Such features of the polymers and processes of the present disclosure are very interesting since it allows for significantly increasing the life cycle of recycled polystyrene. In fact, use of recycled polystyrene is quite often limited in view of the various additives contained therein and they therefore do not meet the requirements for certain uses or applications that can be made with polystyrene. Some manufacturers will also be reluctant to use recycled polystyrene since it can have a too high content of additives and it may affect or diminish the properties of the polystyrene or products made with such recycled polystyrene. This is clearly not the case with the polymers and processes mentioned in the present disclosure. On the contrary, such very low amounts of additives and/or fillers found in the polymers of the present disclosure allow for using these recycled polystyrenes in many different applications and also to recycle them many, many times since merely never reaching high quantities of additives and/or fillers since user of such products is not mandatory to recycle them and to obtain low MFI values.

Thus the polymers and processes of the present disclosure allow for increasing the life cycle of recycled polystyrene (it is possible to recycle it many, many times while maintaining the required specifications and properties) and also they have a very low MFI, while avoiding the use of large quantities of additives and/or fillers.

BRIEF DESCRIPTION OF DRAWINGS

In the following drawings, which represent by way of example only, various embodiments of the disclosure:

FIG. 1 is a schematic diagram of a process according to an embodiment of the present disclosure.

FIG. 2 is a schematic diagram of a process according to another embodiment of the present disclosure.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

Unless otherwise indicated, the definitions and embodiments described in this and other sections are intended to be applicable to all embodiments and aspects of the present disclosure herein described for which they are suitable as would be understood by a person skilled in the art.

As used in the present disclosure, the singular forms “a”, “an” and “the” include plural references unless the content clearly dictates otherwise. For example, an embodiment including “a hydrocarbon polystyrene non-solvent” should be understood to present certain aspects with one hydrocarbon polystyrene non-solvent, or two or more additional hydrocarbon polystyrene non-solvents. In embodiments comprising an “additional” or “second” component, such as an additional or second hydrocarbon polystyrene non-solvent, the second component as used herein is different from the other components or first component. A “third” component is different from the other, first, and second components, and further enumerated or “additional” components are similarly different.

The term “additive” as used herein refers to chemicals added to a polymer to modify at least one physical, biological and/or chemical property. Non-limitative examples of additives are: coloring agents, fillers, flame retardants, lubricants and plasticizers.

In understanding the scope of the present disclosure, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. The term “consisting” and its derivatives, as used herein, are intended to be closed terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The term “consisting essentially of”, as used herein, is intended to specify the presence of the stated features, elements, components, groups, integers, and/or steps as well as those that do not materially affect the basic and novel characteristic(s) of features, elements, components, groups, integers, and/or steps.

Terms of degree such as “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree should be construed as including a deviation of at least ±5% or at least ±10% of the modified term if this deviation would not negate the meaning of the word it modifies.

The term “hydrocarbon polystyrene non-solvent” as used herein refers, for example, to a hydrocarbon-based compound or a mixture thereof in which polystyrene is substantially insoluble. The selection of a suitable hydrocarbon polystyrene non-solvent for the processes of the present disclosure can be made by a person skilled in the art. For example, it will be appreciated by a person skilled in the art that most non-polar additives typically found in polystyrene waste (e.g. hexabromocyclododecane and silicone oils) and ethylbenzene should be substantially soluble in the hydrocarbon polystyrene non-solvent under the conditions used in the processes of the present disclosure to obtain precipitated polystyrene as well as steps which comprise washing with the hydrocarbon polystyrene non-solvent. It will also be appreciated by a person skilled in the art that it may, for example, be useful to select a hydrocarbon polystyrene non-solvent having a boiling point that is around or slightly above the glass transition temperature (T_(g)) of the polystyrene waste being recycled.

The below presented examples are non-limitative and are used to better exemplify the processes of the present disclosure.

An exemplary process flow diagram for a process of the present disclosure is shown in FIG. 1. The exemplified process 10 is a process for recycling polystyrene waste. Referring to FIG. 1, in the exemplified process 10, polystyrene waste can be dissolved 12 in ethylbenzene under conditions to obtain a polystyrene/ethylbenzene mixture. If, for example, the polystyrene/ethylbenzene mixture comprises insoluble material, the polystyrene/ethylbenzene mixture can then optionally be filtered 14 under conditions to remove the insoluble material. The polystyrene/ethylbenzene mixture can then be contacted with (e.g. added to) 16 a first portion of hydrocarbon polystyrene non-solvent under conditions to obtain precipitated polystyrene and a first portion of hydrocarbon waste solution. The precipitated polystyrene can then be separated from the first portion of hydrocarbon waste solution. The dissolving, adding, cooling and separating can optionally be repeated. Then, the precipitated polystyrene can be washed 18 with a second portion of hydrocarbon polystyrene non-solvent under conditions to obtain washed polystyrene and a second portion of hydrocarbon waste solution. The washed polystyrene can then be separated from the second portion of hydrocarbon waste solution. The washed polystyrene can then be washed 20 with a third portion of hydrocarbon polystyrene non-solvent under conditions to obtain twice-washed polystyrene and a third portion of hydrocarbon waste solution. The twice-washed polystyrene can then be separated from the third portion of hydrocarbon waste solution. Surplus hydrocarbon waste solution can then optionally be removed by wringing and/or compressing the twice-washed polystyrene. The twice-washed polystyrene can then optionally be dried 22 under conditions to obtain dried polystyrene. The dried polystyrene can then optionally be packaged 24, for example the process can further comprise processing the dried polystyrene under conditions to obtain polystyrene pellets and the polystyrene pellets can be packaged 24. The ethylbenzene and/or the hydrocarbon polystyrene non-solvent can optionally be recovered 26, for example by a process comprising distilling the first portion of hydrocarbon waste solution, the second portion of hydrocarbon waste solution and/or the third portion of hydrocarbon waste solution under conditions to obtain ethylbenzene and/or hydrocarbon polystyrene non-solvent. The ethylbenzene can optionally be recycled for use in the dissolving 12. The hydrocarbon polystyrene non-solvent can optionally be recycled for use in the contacting (e.g. adding) 16, the first washing 18 and/or the second washing 20.

In some examples of the present disclosure, prior to separating the precipitated polystyrene from the first portion of hydrocarbon waste solution, the process can further comprise cooling the precipitated polystyrene and the first portion of hydrocarbon waste solution.

In some examples of the present disclosure, prior to separating the washed polystyrene from the second portion of hydrocarbon waste solution, the process can further comprise cooling the washed polystyrene and the second portion of hydrocarbon waste solution.

In some examples of the present disclosure, prior to separating the twice-washed polystyrene from the third portion of hydrocarbon waste solution, the process can further comprise cooling the twice-washed polystyrene and the third portion of hydrocarbon waste solution.

An exemplary process flow diagram for another example of a process of the present disclosure is shown in FIG. 2. The exemplified process 100 is a process for recycling polystyrene waste. Referring to FIG. 2, in the exemplified process 100, polystyrene waste can be dissolved 112 in ethylbenzene under conditions to obtain a polystyrene/ethylbenzene mixture. If, for example, the polystyrene/ethylbenzene mixture comprises insoluble material, the polystyrene/ethylbenzene mixture can then optionally be filtered 114 under conditions to remove the insoluble material. The polystyrene/ethylbenzene mixture can then be contacted with (e.g. added to) 116 a first portion of hydrocarbon polystyrene non-solvent under conditions to obtain precipitated polystyrene and a first portion of hydrocarbon waste solution. Referring to FIG. 2, prior to separation, the process can further comprise cooling the precipitated polystyrene and the first portion of hydrocarbon waste solution. The precipitated polystyrene can then be separated from the first portion of hydrocarbon waste solution. The dissolving, adding, cooling and separating can optionally be repeated. Then, the precipitated polystyrene can be washed 118 with a second portion of hydrocarbon polystyrene non-solvent under conditions to obtain washed polystyrene and a second portion of hydrocarbon waste solution. Referring to FIG. 2, prior to separation, the process can further comprise cooling the washed polystyrene and the second portion of hydrocarbon waste solution. The washed polystyrene can then be separated from the second portion of hydrocarbon waste solution. The washed polystyrene can then be washed 120 with a third portion of hydrocarbon polystyrene non-solvent under conditions to obtain twice-washed polystyrene and a third portion of hydrocarbon waste solution. Referring to FIG. 2, prior to separation, the process can optionally further comprise cooling the twice-washed polystyrene and the third portion of hydrocarbon waste solution. The twice-washed polystyrene can then be separated from the third portion of hydrocarbon waste solution. Surplus hydrocarbon waste solution can then optionally be removed by wringing and/or compressing the twice-washed polystyrene. The twice-washed polystyrene can then optionally be dried 122 under conditions to obtain dried polystyrene. The dried polystyrene can then optionally be packaged 124, for example the process can further comprise processing the dried polystyrene under conditions to obtain polystyrene pellets and the polystyrene pellets can be packaged 124. The ethylbenzene and/or the hydrocarbon polystyrene non-solvent can optionally be recovered 126, for example by a process comprising distilling the first portion of hydrocarbon waste solution, the second portion of hydrocarbon waste solution and/or the third portion of hydrocarbon waste solution under conditions to obtain ethylbenzene and/or hydrocarbon polystyrene non-solvent. The ethylbenzene can optionally be recycled for use in the dissolving 112. The hydrocarbon polystyrene non-solvent can optionally be recycled for use in the contacting (e.g. adding) 116, the first washing 118 and/or the second washing 120.

For example, cooling the precipitated polystyrene and the first portion of hydrocarbon waste solution can be carried out at a temperature and for a time until the viscosity of the precipitated polystyrene increases to allow for separation. For example, the cooling (of the precipitated polystyrene and the first portion of hydrocarbon waste solution) can be carried out for a time of from about 10 minutes to about 4 hours. For example, the cooling (of the precipitated polystyrene and the first portion of hydrocarbon waste solution) can be carried out for a time of about 2 hours.

For example, cooling the washed polystyrene and the second portion of hydrocarbon waste solution can be carried out at a temperature and for a time until the viscosity of the precipitated polystyrene increases to allow for separation. For example, the cooling (of the washed polystyrene and the second portion of hydrocarbon waste solution) can be carried out for a time of from about 5 minutes to about 1 hour. For example, the cooling (of the washed polystyrene and the second portion of hydrocarbon waste solution) can be carried out for a time of from about 10 minutes to about 15 minutes.

For example, cooling the twice-washed polystyrene and the third portion of hydrocarbon waste solution can be carried out for a time of from about 5 minutes to about 1 hour. For example, the cooling (of the twice-washed polystyrene and the third portion of hydrocarbon waste solution) can be carried out for a time of from about 10 minutes to about 15 minutes.

The cooling can be carried out by any suitable means, the selection of which can be readily made by a person skilled in the art. For example, the cooling can be carried out by means of a cooling system comprising circulating cold water. For example, the cold water can be at least substantially maintained at a temperature of from about 5° C. to about 10° C.

For example, the polystyrene/ethylbenzene mixture can comprise polystyrene in an amount equal to or less than about 33 wt %, based on the total weight of the polystyrene/ethylbenzene mixture.

For example, the polystyrene/ethylbenzene mixture can comprise polystyrene in an amount of from about 10 wt % to about 30 wt %, based on the total weight of the polystyrene/ethylbenzene mixture.

For example, the polystyrene/ethylbenzene mixture can comprise polystyrene in an amount of from about 14 wt % to about 28 wt %, based on the total weight of the polystyrene/ethylbenzene mixture.

For example, the polystyrene/ethylbenzene mixture can comprise polystyrene in an amount of from about 15 wt % to about 27 wt %, based on the total weight of the polystyrene/ethylbenzene mixture.

For example, the polystyrene/ethylbenzene mixture can comprise polystyrene in an amount of from about 16 wt % to about 25 wt %, based on the total weight of the polystyrene/ethylbenzene mixture.

For example, the polystyrene waste can be dissolved in the ethylbenzene in a container having a chamber containing the ethylbenzene and at least one opening to the chamber for adding the polystyrene waste to the ethylbenzene, and the process can further comprise adding the polystyrene waste to the ethylbenzene contained in the chamber.

For example, the container can further comprise a vent.

For example, the container can further comprise a means to impel the polystyrene waste into the ethylbenzene.

For example, the means to impel the polystyrene waste into the ethylbenzene can comprise a metallic grid inside the container.

For example, the container can further comprise a means to indicate when capacity of the chamber has been reached.

For example, the means to indicate when capacity of the container has been reached can be an indicator light.

For example, the indicator light can be connected to a float switch in the chamber.

For example, the polystyrene/ethylbenzene mixture can comprise insoluble material and the process can further comprise filtering the polystyrene/ethylbenzene mixture under conditions to remove the insoluble material prior to adding the polystyrene/ethylbenzene mixture to the first portion of hydrocarbon polystyrene non-solvent. For example, the insoluble material can be chosen from a polystyrene/butadiene mixture, copolymers of styrene, dust, a sticker, metal, wood, plastic, contaminants and mixtures thereof. For example, the insoluble material can be chosen from dust, sand, dirt, metal, wood, paper, pigment, protein, stickers, polymers that are insoluble in ethylbenzene and mixtures thereof. For example, the polymers that are insoluble in ethylbenzene can be chosen from low density polyethylene (LDPE), high density polyethylene (HDPE), polypropylene (PP), polyethylene terephthalate (PET) and polyvinyl chloride (PVC). The filtering can comprise any suitable filter, the selection of which can be made by a person skilled in the art. For example, the filtering can comprise a multistage filtration process from coarse to fine. For example, the polystyrene/ethylbenzene mixture can be filtered through a filter chosen from a metal mesh filter, a polyolefin bag filter, a polyester bag filter, a cloth filter and a paper filter. For example, butadiene will be soluble in ethylbenzene unless it has been heavily cross linked.

For example, the contacting can comprise adding the polystyrene/ethylbenzene mixture to the first portion of hydrocarbon polystyrene non-solvent.

For example, the conditions to obtain the precipitated polystyrene and the first portion of hydrocarbon waste solution can comprise adding the polystyrene/ethylbenzene mixture to the first portion of hydrocarbon polystyrene non-solvent at the boiling point of the hydrocarbon polystyrene non-solvent and agitating for a time for diffusion of the ethylbenzene from the polystyrene/ethylbenzene mixture into the hydrocarbon polystyrene non-solvent to proceed to a sufficient extent.

For example, the time can be from about 5 minutes to about 10 minutes.

For example, the agitating can comprise stirring with a mechanical stirrer.

For example, the conditions to obtain the precipitated polystyrene and the first portion of hydrocarbon waste solution can comprise adding the polystyrene/ethylbenzene mixture to the first portion of hydrocarbon polystyrene non-solvent at ambient temperature (e.g. a temperature of from about 20° C. to about 30° C. or about 25° C.) then heating to the boiling point of the hydrocarbon polystyrene non-solvent and agitating for a time for diffusion of the ethylbenzene from the polystyrene/ethylbenzene mixture into the hydrocarbon polystyrene non-solvent to proceed to a sufficient extent.

For example, the time can be from about 30 minutes to about 4 hours. For example, the time can be for about 1 hour.

For example, the agitating can comprise stirring with a mechanical stirrer.

For example, greater than about 90 wt % of the ethylbenzene in the polystyrene/ethylbenzene mixture can diffuse into the hydrocarbon polystyrene non-solvent, based on the total weight of the polystyrene/ethylbenzene mixture.

For example, the ratio by volume of the first portion of hydrocarbon polystyrene non-solvent to the polystyrene/ethylbenzene mixture can be from about 2:1 to about 4:1.

For example, the ratio by volume of the first portion of hydrocarbon polystyrene non-solvent to the polystyrene/ethylbenzene mixture can be about 3:1.

For example, the precipitated polystyrene can be separated from the first portion of hydrocarbon waste solution by a process comprising decanting the first portion of hydrocarbon waste solution from the precipitated polystyrene.

For example, the conditions to obtain the washed polystyrene and the second portion of hydrocarbon waste solution can comprise adding the second portion of hydrocarbon polystyrene non-solvent to the precipitated polystyrene at the boiling point of the hydrocarbon polystyrene non-solvent and agitating for a time for diffusion of the ethylbenzene from the precipitated polystyrene into the hydrocarbon polystyrene non-solvent to proceed to a sufficient extent.

For example, the time can be from about 1 minute to about 15 minutes. For example, the time can be about 10 minutes. For example, the time can be from about 2 minutes to about 5 minutes. For example, the agitating can comprise stirring with a mechanical stirrer.

For example, the conditions to obtain the washed polystyrene and the second portion of hydrocarbon waste solution can comprise adding the second portion of hydrocarbon polystyrene non-solvent to the precipitated polystyrene at ambient temperature (e.g. a temperature of from about 20° C. to about 30° C. or about 25° C.) then heating to the boiling point of the hydrocarbon polystyrene non-solvent and agitating for a time for diffusion of the ethylbenzene from the precipitated polystyrene into the hydrocarbon polystyrene non-solvent to proceed to a sufficient extent.

For example, the time can be from about 15 minutes to about 2 hours. For example, the time can be about 30 minutes. For example, the agitating can comprise stirring with a mechanical stirrer.

For example, the washed polystyrene can comprise less than about 0.3 wt % ethylbenzene. For example, the washed polystyrene can comprise less than about 0.1 wt % ethylbenzene.

For example, the ratio by volume of the second portion of hydrocarbon polystyrene non-solvent to the precipitated polystyrene can be from about 1:2 to about 2:1. For example, the ratio by volume of the second portion of hydrocarbon polystyrene non-solvent to the precipitated polystyrene can be about 1:1.

For example, the washed polystyrene can be separated from the second portion of hydrocarbon waste solution by a process comprising decanting the second portion of hydrocarbon waste solution from the washed polystyrene.

For example, the conditions to obtain the twice-washed polystyrene and the third portion of hydrocarbon waste solution can comprise adding the third portion of hydrocarbon polystyrene non-solvent to the washed polystyrene at the boiling point of the hydrocarbon polystyrene non-solvent and agitating for a time for diffusion of the ethylbenzene from the washed polystyrene into the hydrocarbon polystyrene non-solvent to proceed to a sufficient extent.

For example, the time can be from about 1 minute to about 10 minutes. For example, the time can be about 5 minutes. For example, the agitating can comprise stirring with a mechanical stirrer.

For example, the conditions to obtain the twice-washed polystyrene and the third portion of hydrocarbon waste solution can comprise adding the third portion of hydrocarbon polystyrene non-solvent to the washed polystyrene at ambient temperature (e.g. a temperature of from about 20° C. to about 30° C. or about 25° C.) then heating to the boiling point of the hydrocarbon polystyrene non-solvent and agitating for a time for diffusion of the ethylbenzene from the washed polystyrene into the hydrocarbon polystyrene non-solvent to proceed to a sufficient extent.

For example, the time can be from about 15 minutes to about 2 hours. For example, the time can be about 30 minutes. For example, the agitating can comprise stirring with a mechanical stirrer.

For example, the twice-washed polystyrene can comprise less than about 0.1 wt % ethylbenzene. For example, the twice-washed polystyrene can comprise less than about 0.05 wt % ethylbenzene.

For example, the ratio by volume of the third portion of hydrocarbon polystyrene non-solvent to the washed polystyrene can be from about 1:2 to about 2:1. For example, the ratio by volume of the third portion of hydrocarbon polystyrene non-solvent to the washed polystyrene can be about 1:1.

For example, the twice-washed polystyrene can be separated from the third portion of hydrocarbon waste solution by a process comprising decanting the third portion of hydrocarbon waste solution from the twice-washed polystyrene.

For example, after separating the twice-washed polystyrene from the third portion of hydrocarbon waste solution and prior to drying, the process can further comprise removing surplus hydrocarbon waste solution by wringing and/or compressing the twice-washed polystyrene.

For example, at least one of the first portion of hydrocarbon polystyrene non-solvent, the second portion of hydrocarbon polystyrene non-solvent and the third portion of hydrocarbon polystyrene non-solvent can comprise, consist essentially of or consist of a hydrocarbon polystyrene non-solvent having a boiling point at 1 atm of pressure of from about 98° C. to about 110° C. or about 105° C. to about 110° C.

For example, the first portion of hydrocarbon polystyrene non-solvent, the second portion of hydrocarbon polystyrene non-solvent and the third portion of hydrocarbon polystyrene non-solvent can comprise, consist essentially of or consist of a C₆-C₈ alkane or a petroleum distillate.

For example, the first portion of hydrocarbon polystyrene non-solvent, the second portion of hydrocarbon polystyrene non-solvent and the third portion of hydrocarbon polystyrene non-solvent can comprise, consist essentially of or consist of a C₆-C₈ alkane.

For example, the C₆-C₈ alkane can be heptane. For example, the heptane can be n-heptane. For example, the C₆-C₈ alkane can be hexane. For example, the hexane can be isohexane.

For example, the first portion of hydrocarbon polystyrene non-solvent, the second portion of hydrocarbon polystyrene non-solvent and the third portion of hydrocarbon polystyrene non-solvent can comprise, consist essentially of or consist of a petroleum distillate.

For example, the first portion of hydrocarbon polystyrene non-solvent, the second portion of hydrocarbon polystyrene non-solvent and the third portion of hydrocarbon polystyrene non-solvent can comprise, consist essentially of or consist of n-heptane.

For example, the first portion of hydrocarbon polystyrene non-solvent, the second portion of hydrocarbon polystyrene non-solvent and the third portion of hydrocarbon polystyrene non-solvent can all be the same hydrocarbon polystyrene non-solvent.

For example, the first portion of hydrocarbon polystyrene non-solvent, the second portion of hydrocarbon polystyrene non-solvent and the third portion of hydrocarbon polystyrene non-solvent can all be different hydrocarbon polystyrene non-solvents.

For example, the second portion of hydrocarbon polystyrene non-solvent and the third portion of hydrocarbon polystyrene non-solvent can be the same hydrocarbon polystyrene non-solvent and the first portion of hydrocarbon polystyrene non-solvent can be a different hydrocarbon polystyrene non-solvent.

For example, the second portion of hydrocarbon polystyrene non-solvent and the third portion of hydrocarbon polystyrene non-solvent can comprise, consist essentially of or consist of n-heptane and the first portion of hydrocarbon polystyrene non-solvent can comprise, consist essentially of or consist of n-hexane.

For example, the conditions to obtain the dried polystyrene can comprise drying the twice-washed polystyrene for a temperature and time for removal of remaining hydrocarbon polystyrene non-solvent to proceed to a sufficient extent. For example, the twice-washed polystyrene can be dried at a temperature of from about 115° C. to about 125° C. For example, the twice-washed polystyrene can be dried at a temperature of about 120° C. For example, the twice-washed polystyrene can be dried at a temperature of from about 90° C. to about 110° C. For example, the twice-washed polystyrene can be dried at a temperature of about 100° C. For example, the conditions to obtain the dried polystyrene can further comprise applying vacuum.

For example, the conditions to obtain the dried polystyrene can comprise drying the twice-washed polystyrene using an infrared dryer for a time for removal of remaining hydrocarbon polystyrene non-solvent to proceed to a sufficient extent.

For example, the polystyrene waste can comprise polar impurities and the process can further comprise washing the polystyrene waste with a polar organic solvent under conditions to remove the polar impurities.

For example, the polar organic solvent can comprise, consist essentially of or consist of methanol or ethanol. For example, the polar organic solvent can comprise, consist essentially of or consist of methanol. For example, the polar organic solvent can comprise, consist essentially of or consist of ethanol.

For example, the process can further comprise distilling the first portion of hydrocarbon waste solution, the second portion of hydrocarbon waste solution and/or the third portion of hydrocarbon waste solution under conditions to obtain ethylbenzene and/or hydrocarbon polystyrene non-solvent.

For example, the process can further comprise recycling the ethylbenzene for use in the dissolving step.

For example, the process can further comprise recycling the hydrocarbon polystyrene non-solvent for use in the adding step, the first washing step and/or the second washing step.

For example, the process can further comprise processing the dried polystyrene under conditions to obtain polystyrene pellets. For example, the conditions to obtain the polystyrene pellets can comprise extruding the dried polystyrene at a temperature of from about 140° C. to about 160° C.

For example, the process can further comprise packaging the polystyrene pellets. Suitable means to package the polystyrene pellets can be selected by a person skilled in the art.

For example, the process can further comprise adding an antioxidant during the dissolving step, the adding step, the first washing step and/or the second washing step. For example, the process can further comprise adding an antioxidant during the dissolving step.

For example, the antioxidant can comprise, consist essentially of or consist of octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionate.

For example, the antioxidant can be added in an amount of from about 0.1 wt % to about 2 wt %, based on the total weight of the polystyrene. For example, the antioxidant can be added in an amount of about 1 wt %, based on the total weight of the polystyrene. For example, the antioxidant can be added in an amount of from about 0.5 wt % to about 2 wt %, based on the total weight of the polystyrene.

For example, the process can further comprise adding an additive for lowering or increasing melt flow index to the polystyrene/ethylbenzene mixture. For example, the process can further comprise adding an additive for lowering melt flow index to the polystyrene/ethylbenzene mixture.

For example, the additive for lowering melt flow index can comprise, consist essentially of or consist of lime, talc, silicon oxide, silicon hydroxide, aluminum oxide, aluminum hydroxide, or combinations thereof. For example, the additive for lowering melt flow index can comprise, consist essentially of or consist of lime. For example, the additive for lowering melt flow index can comprise, consist essentially of or consist of talc.

For example, the additive for increasing melt flow index can comprise, from about 0.0001 wt % to about 1 wt % of silicon oil. For example, silicon oil can be added from about 0.01 wt % to 0.1 wt %.

For example, the additive for lowering melt flow index can be added in an amount of from about 0.5 wt % to about 25 wt %, based on the total weight of the polystyrene. For example, the additive for lowering melt flow index can be added in an amount of about 0.5 wt % to about 5 wt %, based on the total weight of the polystyrene. For example, the additive for lowering melt flow index can be added in an amount of about 1 wt %, based on the total weight of the polystyrene.

For example, the polystyrene waste can be post-industrial waste, post-consumer waste or a combination thereof. For example, the polystyrene waste can be post-industrial waste. For example, the polystyrene waste can be post-consumer waste. For example, the polystyrene waste can be a combination of post-industrial waste and post-consumer waste.

For example, the polystyrene waste can comprise, consist essentially of or consist of expanded polystyrene. For example, the polystyrene waste can comprise, consist essentially of or consist of white, expanded polystyrene. For example, the polystyrene waste can comprise, consist essentially of or consist of compressed polystyrene.

For example, the process can further comprise grinding the polystyrene waste prior to dissolving.

For example, the polystyrene/ethylbenzene mixture can be obtained at a first location and the process can further comprise transporting the polystyrene/ethylbenzene mixture to a second location wherein subsequent steps in the process can be carried out.

For example, the dissolving can be carried out at a temperature of from about 0° C. to about 100° C. For example, the dissolving can be carried out at a temperature of from about 20° C. to about 30° C. For example, the dissolving can be carried out at a temperature of from about 75° C. to about 85° C. For example, the dissolving can be carried out at a temperature of about 80° C.

In some examples of the present disclosure, the dissolving can be carried out for a time of from about 30 minutes to about 4 hours. For example, the dissolving can be carried out for a time of about 1 hour.

For example, the contacting/adding can be carried out at a temperature of from about 80° C. to about 120° C. For example, the contacting/adding can be carried out at a temperature of from about 80° C. to about 90° C. For example, the contacting/adding can be carried out at a temperature of about 85° C. For example, the first portion of hydrocarbon polystyrene non-solvent can be heptane and the contacting/adding can be carried out at a temperature of from about 80° C. to about 105° C., about 85° C. to about 100° C., about 80° C. to about 90° C. or about 85° C.

For example, the contacting/adding can comprise contacting/adding the polystyrene/ethylbenzene mixture with/to the first portion of hydrocarbon polystyrene non-solvent at ambient temperature (e.g. a temperature of about 20° C. to about 30° C. or about 25° C.) then heating for a suitable time (e.g. from about 5 minutes to about 1 hour or about 30 minutes) at a temperature of from about 80° C. to about 120° C., about 95° C. to about 105° C. or about 100° C. For example, the first portion of hydrocarbon polystyrene non-solvent can be heptane and the contacting/adding can comprise contacting/adding the polystyrene/ethylbenzene mixture with/to the first portion of hydrocarbon polystyrene non-solvent at ambient temperature (e.g. a temperature of about 20° C. to about 30° C. or about 25° C.) then heating for a suitable time (e.g. from about 5 minutes to about 1 hour or about 30 minutes) at a temperature of from about 95° C. to about 105° C. or about 100° C.

For example, the washing of the precipitated polystyrene with the second portion of hydrocarbon polystyrene non-solvent can be carried out at a temperature of from about 80° C. to about 120° C. For example, the washing of the precipitated polystyrene with the second portion of hydrocarbon polystyrene non-solvent can be carried out at a temperature of from about 80° C. to about 90° C. For example, the washing of the precipitated polystyrene with the second portion of hydrocarbon polystyrene non-solvent can be carried out at a temperature of about 85° C. For example, the second portion of hydrocarbon polystyrene non-solvent can be heptane and the washing of the precipitated polystyrene with the second portion of hydrocarbon polystyrene non-solvent can be carried out at a temperature of about 80° C. to about 105° C., about 85° C. to about 100° C., about 80° C. to about 90° C. or about 85° C.

For example, the washing of the precipitated polystyrene with the second portion of the hydrocarbon polystyrene non-solvent can comprise contacting/adding the second portion of the hydrocarbon polystyrene non-solvent with/to the precipitated polystyrene at ambient temperature (e.g. a temperature of about 20° C. to about 30° C. or about 25° C.) then heating for a suitable time (e.g. from about 5 minutes to about 1 hour or about 30 minutes) at a temperature of from about 80° C. to about 120° C., about 95° C. to about 105° C. or about 100° C. For example, the second portion of hydrocarbon polystyrene non-solvent can be heptane and the washing of the precipitated polystyrene with the second portion of the hydrocarbon polystyrene non-solvent can comprise contacting/adding the second portion of the hydrocarbon polystyrene non-solvent with/to the precipitated polystyrene at ambient temperature (e.g. a temperature of about 20° C. to about 30° C. or about 25° C.) then heating for a suitable time (e.g. from about 5 minutes to about 1 hour or about 30 minutes) at a temperature of from about 95° C. to about 105° C. or about 100° C.

For example, the washing of the washed polystyrene with the third portion of hydrocarbon polystyrene non-solvent can be carried out at a temperature of from about 80° C. to about 120° C. For example, the washing of the washed polystyrene with the third portion of hydrocarbon polystyrene non-solvent can be carried out at a temperature of from about 80° C. to about 90° C. For example, the washing of the washed polystyrene with the third portion of hydrocarbon polystyrene non-solvent can be carried out at a temperature of about 85° C. For example, the third portion of hydrocarbon polystyrene non-solvent can be heptane and the washing of the washed polystyrene with the third portion of hydrocarbon polystyrene non-solvent can be carried out at a temperature of about 80° C. to about 105° C., about 85° C. to about 100° C., about 80° C. to about 90° C. or about 85° C.

For example, the washing of the washed polystyrene with the third portion of the hydrocarbon polystyrene non-solvent can comprise contacting/adding the third portion of the hydrocarbon polystyrene non-solvent with/to the washed polystyrene at ambient temperature (e.g. a temperature of about 20° C. to about 30° C. or about 25° C.) then heating for a suitable time (e.g. from about 5 minutes to about 1 hour or about 30 minutes) at a temperature of from about 80° C. to about 120° C., about 95° C. to about 105° C. or about 100° C. For example, the third portion of hydrocarbon polystyrene non-solvent can be heptane and the washing of the washed polystyrene with the third portion of the hydrocarbon polystyrene non-solvent can comprise contacting/adding the third portion of the hydrocarbon polystyrene non-solvent with/to the washed polystyrene at ambient temperature (e.g. a temperature of about 20° C. to about 30° C. or about 25° C.) then heating for a suitable time (e.g. from about 5 minutes to about 1 hour or about 30 minutes) at a temperature of from about 95° C. to about 105° C. or about 100° C.

The present disclosure also includes recycled polystyrene prepared according to a process for recycling polystyrene waste of the present disclosure.

For example, the waste polystyrene can comprise other copolymers. For example, it can comprise butadiene, (HIPS), be a copolymer of styrene and acrylonitrile (SAN) or acrylonitrile, butadiene and styrene (ABS). For example, the waste polystyrene can be a polystyrene-co-butadiene copolymer. In other examples of the present disclosure, the waste polystyrene does not comprise other copolymers.

For example, embodiments relating to the recycled polystyrene of the present disclosure can be varied as discussed herein in respect of the processes for recycling polystyrene waste of the present disclosure.

For example, the recycled polystyrene can have a melt flow index of less than about 40 g/10 min. For example, the recycled polystyrene can have a melt flow index of from about 3 to about 30 g/10 min. For example, the recycled polystyrene can have a melt flow index of from about 3 to about 25 g/10 min. For example, the recycled polystyrene can have a melt flow index of less than about 25 g/10 min. For example, the recycled polystyrene can have a melt flow index of from about 10 to about 20 g/10 min.

For example, the recycled polystyrene can have a melt flow index of less than about 40 g/10 min. For example, the recycled polystyrene can have a melt flow index of from about 5 to about 30 g/10 min. For example, the recycled polystyrene can have a melt flow index of from about 5 to about 25 g/10 min. For example, the recycled polystyrene can have a melt flow index of less than about 25 g/10 min. For example, the recycled polystyrene can have a melt flow index of from about 10 to about 20 g/10 min.

For example, the recycled polystyrene can have a melt flow index of less than about 30 g/10 min. For example, the recycled polystyrene can have a melt flow index of from about 3 to about 25 g/10 min. For example, the recycled polystyrene can have a melt flow index of from about 1 to about 15 g/10 min. For example, the recycled polystyrene can have a melt flow index of from about 10 to about 15 g/10 min. For example, the recycled polystyrene can have a melt flow index of from about 5 to about 12 g/10 min. For example, the recycled polystyrene can have a melt flow index of from about 2 to about 12 g/10 min. For example, the recycled polystyrene can have a melt flow index of less than about 15 g/10 min. For example, the recycled polystyrene can have a melt flow index of less than about 12 g/10 min.

For example, the recycled polystyrene can have a content of additive(s) of less than about 5 wt %.

For example, the recycled polystyrene can have a content of additive(s) of less than about 3 wt %.

For example, the recycled polystyrene can have a content of additive(s) of less than about 2 wt %.

For example, the recycled polystyrene can have a content of additive(s) of less than about 1 wt %.

For example, the recycled polystyrene can have a content of additive(s) of less than about 0.5 wt %.

For example, the recycled polystyrene can have a content of additive(s) of less than about 0.1 wt %.

For example, the recycled polystyrene can have a content of additive(s) of less than about 0.05 wt %.

For example, the recycled polystyrene can have a content of additive(s) of about 0.05 wt % to about 1 wt %.

For example, the recycled polystyrene can have a content of additive(s) of about 0.1 wt % to about 1 wt %.

For example, the recycled polystyrene can have a filler content of less than about 5 wt %.

For example, the recycled polystyrene can have a filler content of less than about 3 wt %.

For example, the recycled polystyrene can have a filler content of less than about 2 wt %.

For example, the recycled polystyrene can have a filler content of less than about 1 wt %.

For example, the recycled polystyrene can have a filler content of less than about 0.5 wt %.

For example, the recycled polystyrene can have a filler content of less than about 0.1 wt %.

For example, the recycled polystyrene can have a filler content of less than about 0.05 wt %.

For example, the recycled polystyrene can have a filler content of about 0.05 wt % to about 1 wt %.

For example, the recycled polystyrene can have a filler content of about 0.1 wt % to about 1 wt %.

For example, the filler can be an inorganic filler.

For example, the recycled polymer can be obtained by recycling a polystyrene waste by involving a treatment with a solvent and a non-solvent.

For example, the recycled polymer can be been obtained by recycling a polystyrene waste by involving a treatment with a solvent that is ethylbenzene and a hydrocarbon polystyrene non-solvent that is C₆-C₈ alkane or mixtures thereof.

For example, the polystyrene waste can comprise polystyrene having an average molecular weight of about 200,000 to about 350,000 g/mol.

For example, the polystyrene waste can comprise polystyrene having an average molecular weight of about 230,000 to about 260,000 g/mol.

For example, the polystyrene waste can comprise polystyrene having an average molecular weight of about 260,000 to about 300,000 g/mol.

For example, the recycled polystyrene can be transparent.

For example, the recycled polystyrene can be clear.

For example, the recycled polystyrene can be substantially transparent.

For example, the recycled polystyrene can be at least substantially transparent.

For example, the recycled polystyrene can be obtained by any of the processes and/or methods described in the present disclosure.

There is also provided the use of the recycled polystyrenes of the present disclosure for preparing a mixture comprising the recycled polystyrene and a virgin polystyrene.

There is also provided a method of using the recycled polystyrenes of the present disclosure comprising mixing the recycled polystyrene with a virgin polystyrene.

For example, the mixture can comprise at least about 10 wt %, at least about 15 wt %, at least about 20 wt %, about 1 wt % to about 50 wt %, about 5 wt % to about 50 wt %, or about 5 wt % to about 30 wt % of the recycled polystyrene.

For example, the recycled polystyrene can comprise other copolymers. For example, it can comprise butadiene (HIPS), be a copolymer of styrene and acrylonitrile (SAN) or acrylonitrile, butadiene and styrene (ABS). For example, the recycled polystyrene can be a polystyrene-co-butadiene copolymer. In other examples of the present disclosure, the waste polystyrene does not comprise other copolymers.

For example, recycling of the polystyrene or converting of the polystyrene waste into recycled polystyrene can be carried out by a method/process as defined in the present disclosure.

EXAMPLES Example 1: Recycling of Polystyrene Waste

In the present studies, polystyrene waste was recycled in a process which included five main steps, according to the following sequence:

-   -   1. Solubilisation of the polystyrene in ethylbenzene     -   2. Filtration of the polystyrene (PS)/ethylbenzene mixture to         remove undissolved materials     -   3. Washing with a non-polar solvent that is a non-solvent to PS     -   4. Drying     -   5. Forming and packaging PS plastic beads

In the first step (solubilisation), polystyrene waste such as industrial post-consumption expanded polystyrene was dissolved in ethylbenzene. In the solubilisation step, the polystyrene loses its structural properties and a reduction of the volume it occupies occurs. Various non-polar additives including hexabromocyclododecane (HBCD) and the silicone oils used in its manufacture are dissolved in the ethylbenzene solvent. This step was performed in a closed, vented tank called the dissolution module. An object of the module is to maximize the amount of polystyrene that can be solubilised within a given period of time. For example, a metallic grid inside the dissolution module can push the expanded polystyrene objects into ethylbenzene which can reduce, for example, dissolution time from hours to minutes.

The third step (washing) had objectives which included: (1) the precipitation of the polystyrene; (2) recovery of the ethylbenzene in order to reuse it in step 1; and (3) elimination of the different additives that may alter the mechanical properties of the recycled polystyrene. This step comprised first precipitating the solubilised polystyrene with hexane, heptane or any other hydrocarbon with a suitable boiling point. While heptane was observed to provide the best results in the washing step, other hydrocarbons may also be useful. Hexane and octane were tested in the present studies. Petroleum distillates with a boiling point of from about 100° C. to about 120° C. may also be useful and may provide, for example, reduced process and/or operating costs.

For example, the solvent may have a boiling point around or slightly above the T_(g) for the polystyrene waste. While the T_(g) of polystyrene may vary, for example as a function of molecular weight, the T_(g) for the polystyrene waste is typically about 98° C. It will be appreciated by a person skilled in the art that there is typically only a small variation of T_(g) with molecular weight or polydispersity for most polystyrenes used in the fabrication of industrial polystyrene objects. Accordingly, the solvent may have a boiling point up to about 110° C., for example a boiling point of about 105° C. to about 110° C. at 1 atm pressure. A suitable hydrocarbon solvent may, for example enable more than 90% of the ethylbenzene to migrate into it and is a non-solvent for polystyrene.

To carry out the first washing step (i.e. precipitating the polystyrene), the mixture of solubilised polystyrene in ethylbenzene was slowly poured into a double wall stainless steel tank containing the hydrocarbon at its boiling temperature. In an exemplary experiment hexane at its boiling temperature (69° C.) was used for this step. In other exemplary experiments heptane at its boiling temperature (98° C.) was used for this step. The entire mixture was moderately stirred through use of a mechanical stirrer. The volume of polystyrene/ethylbenzene solution added to the hydrocarbon was in a polystyrene/ethylbenzene solution to hydrocarbon ratio by volume of 1:3. Under these conditions, the polystyrene may precipitate in the form of a sticky white paste. However, it was found that it was more likely to form flakes of PS during the stirring instead of a sticky paste. The stirring time (from about 5 minutes to about 10 minutes) allowed for a useful amount of diffusion of the ethylbenzene into the hydrocarbon. However, due to great affinity between the ethylbenzene and the polystyrene, the precipitated polystyrene was observed to remain very malleable and tended to stay in the solvent mixture instead of separating efficiently. In such cases, it was found that a cooling process could be used to increase the viscosity of the precipitated polystyrene and to foster the separation of the precipitated polystyrene and the first portion of solvent mixture. For example, by using a cooling system in the double walled stainless steel tank. For example, cold water (5° C. to 10° C.) can be used to cool the tank with the precipitated polystyrene and the first portion of solvent mixture. The cooling could be over a time of about 10 minutes to about 15 minutes or longer, for example about 2 hours. After precipitation and optionally cooling, the solvent mixture supernatant was removed by a simple decantation, after which it was possible to perform a second washing of the precipitated polystyrene.

The second washing was performed in the same tank with heptane. A defined volume of heptane having a boiling temperature of 98° C. was introduced into the tank, according to a polystyrene:heptane ratio by volume of 1:1. The whole mixture was boiled at atmospheric pressure under moderate mechanical stirring over about 2 minutes to about 5 minutes. Using a different hydrocarbon in the second wash than in the first wash increased the malleability of the polystyrene which, for example, increased diffusion of the remaining ethylbenzene solvent out of the precipitated polystyrene and into the hydrocarbon. The cooling system can also be used after the second wash to increase the viscosity of the precipitated polystyrene and allow for an easier separation between the solvent mixture and the polystyrene (e.g. cooling for a time of from about 10 minutes to about 15 minutes). After washing and optionally cooling, the supernatant solvent mixture was removed by a simple decantation. According to the calculations of washing efficiency, less than 0.1% ethylbenzene remained in the precipitated polystyrene at this stage.

A third washing with boiling heptane was used in order to further reduce the presence of ethylbenzene in the polystyrene. The presence of residual solvent may, for example, affect the melt index, also called melt flow index (MFI). The degree of washing efficiency is inversely proportional to the MFI. The washing conditions used were the same as in the second washing step. The polystyrene tended to stay as a solid paste compared to the precipitation step and the solvent mixture can be removed more easily without losing precipitated material. Accordingly, the cooling step may not be needed to have efficient separation for the third wash, for example.

The recovered solvent mixture contained hexane, heptane, ethylbenzene and/or any other hydrocarbon solvent used as well as non-polar additives extracted from the PS. The proportion of ethylbenzene and additives was higher in the first solvent mixture than in the second and third solvent mixtures. Fractional distillation was used to separate the different products. The ethylbenzene was reused for the solubilisation step while hexane and heptane were reused in the washing steps. The recovered additives were considered to be waste for disposal.

The fourth step (drying) comprised drying the polystyrene paste, which contained about 5-37% heptane in a dryer at a temperature of 120° C. An objective was to remove substantially all of the remaining solvent without altering the quality of the polymer.

The fifth step (packaging) comprised cutting the dried polystyrene into small pellets suitable for the distribution of the product to customers. A pelletizer as commonly used in the industry was utilized to control the size and the shape of the final product.

In order to limit the PS degradation which is mainly due to oxidation as observed during the drying and extrusion steps, a commercial antioxidant such as Irganox™ 1076 (octadecyl-3-(3,5-di-tert.butyl-4-hydroxyphenyl)-propionate) can be added in a proportion of about 1%, based on the weight of the polystyrene. This compound is acceptable for food applications, has a melting point of 50° C. and can be added at various times in the process: i.e. with the ethylbenzene, in the washing steps and/or at the final extrusion step.

Example 2: Polystyrene Crystal

A solution of polystyrene (PS), with a PS concentration of 20%, was prepared by dissolving 40 g of PS crystal, average Mw=170,000, in 160 g of ethyl benzene. The solution was heated to 80° C., with magnetic stirring, for 2 h. The solution was allowed to return to 25° C. A fraction of 79 g of PS solution in ethyl benzene was added to 300 ml of cold heptane and heated with stirring for 30 minutes at 100° C. The solution was allowed to return to room temperature. The solvent mixture was removed by decantation leaving only the white PS paste at the bottom of the beaker. Fresh heptane (300 ml) was added to the PS white paste and the solvent was heated to 100° C. with stirring for 30 minutes. The solvent was allowed to return to 25° C. The PS paste was washed a third time with 300 ml of heptane under identical conditions. The PS paste, 26.1 g, was dried 4 days in an oven heated at 100. The PS weight was 17.7 g after 4 days of drying.

Example 3: Recycling of Post-Consumer Expanded Polystyrene

I. Experimental

A solution of polystyrene (PS), with a PS concentration of 20%, was prepared by dissolving 20 g of expanded polystyrene from boxes of furniture in 80 g of ethylbenzene. The solution was heated to 80° C., with magnetic stirring, for 1 h. The polystyrene/ethyl benzene solution was added to 175 mL of cold heptane and heated to 80° C. for 1 h, with magnetic stirring to form a precipitate white paste of PS. The solution was allowed to return to room temperature and a cooling process (around 5° C. to 10° C.) was used to increase the viscosity of the precipitated polystyrene over a period of 2 hours. The solvent mixture was removed by decantation leaving only the white PS paste at the bottom of the flask. Fresh heptane (150 ml) was added to the PS white paste and the solvent was heated to 80° C. with magnetic stirring for 30 minutes. The solvent was allowed to return to room temperature and another cooling step (around 5° C. to 10° C.) was used to separate with more efficiency the solvent of the precipitated PS. The PS paste was washed a second time with (150 ml) of heptane under identical conditions and the twice-washed polystyrene paste was separated from the solvent mixture. The PS paste, 30.02 g, was dried under vacuum for 4 hours at 100° C. The recycled PS weight was 19.47 g after drying.

II. Results and Discussion

Ethylbenzene seems to have a very good affinity with the polystyrene which may, for example cause the PS to stay more malleable and to have still a significant amount of ethylbenzene left trapped inside after the precipitation (hot and at room temperature). So it can be difficult to extract the solvent mixture without losing some PS (it tended to go with the heptane/ethylbenzene mix) and if the precipitate is in the form of flakes it's more difficult to get a good separation. So to increase the separation of the solid/liquid, the solution was cooled to around 5° C. to 10° C. (e.g. 30 min to 1 h), so that the PS viscosity will increase and the solvent mixture could be separated more easily without losing any PS. This cooling step can be carried out again after the first washing to ensure to not lose any PS with the solvent. After the second washing, it was found to be optional because there is typically less than 1% of ethylbenzene left in the PS at this point, so the PS tends to stay more solid and to be separated without any trouble.

This affinity of ethylbenzene with PS compared to previous results with p-cymene with PS was unexpected. While not wishing to be limited by theory, it may, for example, allow for advantages in recycling since ethylbenzene separates the polymer chains even better and therefore contaminants such as mineral oils, flame retardants etc. may be removed more easily. Additionally, ethylbenzene has a boiling temperature (136.2° C.) that is lower than the cymene (177° C.) so in the case where it would remain slightly in the polystyrene, passing in the oven under vacuum at a suitable temperature may, for example, evaporate the maximum residual solvent and thus prepare a better quality of the final PS using less energy.

While a description was made with particular reference to the specific embodiments, it will be understood that numerous modifications thereto will appear to those skilled in the art. Accordingly, the above description and accompanying drawings should be taken as specific examples and not in a limiting sense. 

What is claimed is:
 1. A process for recycling polystyrene waste, comprising: dissolving said polystyrene waste in ethylbenzene to obtain a polystyrene/ethylbenzene mixture; contacting said polystyrene/ethylbenzene mixture with a first portion of hydrocarbon polystyrene non-solvent to obtain precipitated polystyrene and a first portion of hydrocarbon waste solution; separating said precipitated polystyrene from said first portion of hydrocarbon waste solution; optionally repeating said dissolving, adding, and separating; washing said precipitated polystyrene with a second portion of hydrocarbon polystyrene non-solvent to obtain washed polystyrene and a second portion of hydrocarbon waste solution; separating said washed polystyrene from said second portion of hydrocarbon waste solution; washing said washed polystyrene with a third portion of hydrocarbon polystyrene non-solvent to obtain twice-washed polystyrene and a third portion of hydrocarbon waste solution; separating said twice-washed polystyrene from said third portion of hydrocarbon waste solution; and optionally drying said twice-washed polystyrene under conditions to obtain dried polystyrene; wherein the recycled polystyrene has a melt flow index of about 1 g/10 min to less than 40 g/10 min.
 2. The process of claim 1, wherein prior to separating said precipitated polystyrene from said first portion of hydrocarbon waste solution, said process further comprises cooling said precipitated polystyrene and said first portion of hydrocarbon waste solution.
 3. The process of claim 1, wherein prior to separating said washed polystyrene from said second portion of hydrocarbon waste solution, said process further comprises cooling said washed polystyrene and said second portion of hydrocarbon waste solution.
 4. The process of claim 1, wherein prior to separating said twice-washed polystyrene from said third portion of hydrocarbon waste solution, said process further comprises cooling said twice-washed polystyrene and said third portion of hydrocarbon waste solution.
 5. A process for recycling polystyrene waste, comprising: dissolving said polystyrene waste in ethylbenzene to obtain a polystyrene/ethylbenzene mixture; contacting said polystyrene/ethylbenzene mixture with a first portion of hydrocarbon polystyrene non-solvent to obtain precipitated polystyrene and a first portion of hydrocarbon waste solution; cooling said precipitated polystyrene and said first portion of hydrocarbon waste solution; separating said precipitated polystyrene from said first portion of hydrocarbon waste solution; optionally repeating said dissolving, adding, cooling and separating; washing said precipitated polystyrene with a second portion of hydrocarbon polystyrene non-solvent to obtain washed polystyrene and a second portion of hydrocarbon waste solution; cooling said washed polystyrene and said second portion of hydrocarbon waste solution; separating said washed polystyrene from said second portion of hydrocarbon waste solution; washing said washed polystyrene with a third portion of hydrocarbon polystyrene non-solvent to obtain twice-washed polystyrene and a third portion of hydrocarbon waste solution; optionally cooling said twice-washed polystyrene and said third portion of hydrocarbon waste solution; separating said twice-washed polystyrene from said third portion of hydrocarbon waste solution; and optionally drying said twice-washed polystyrene to obtain dried polystyrene; wherein the recycled polystyrene has a melt flow index of about 1 g/10 min to less than 40 g/10 min.
 6. The process of claim 5, wherein said process comprises cooling said twice-washed polystyrene and said third portion of hydrocarbon waste solution.
 7. The process of claim 6, wherein cooling said precipitated polystyrene and said first portion of hydrocarbon waste solution is carried out at a temperature and for a time until the viscosity of said precipitated polystyrene increases to allow for separation.
 8. The process of claim 3, wherein cooling said washed polystyrene and said second portion of hydrocarbon waste solution is carried out at a temperature and for a time until the viscosity of said precipitated polystyrene increases to allow for separation.
 9. The process of claim 1, wherein said polystyrene/ethylbenzene mixture comprises polystyrene in an amount of less than 33 wt %, based on the total weight of said polystyrene/ethylbenzene mixture.
 10. The process of claim 1, wherein said polystyrene/ethylbenzene mixture comprises polystyrene in an amount of from about 10 wt % to about 30 wt %, based on the total weight of said polystyrene/ethylbenzene mixture.
 11. The process of claim 5, wherein said polystyrene/ethylbenzene mixture comprises polystyrene in an amount of from about 16 wt % to about 25 wt %, based on the total weight of said polystyrene/ethylbenzene mixture.
 12. The process of claim 5, wherein said polystyrene waste is dissolved in said ethylbenzene in a container having a chamber containing said ethylbenzene and at least one opening to said chamber for adding said polystyrene waste to said ethylbenzene, and said process further comprises adding said polystyrene waste to said ethylbenzene contained in said chamber.
 13. The process of claim 1, wherein process comprises adding said polystyrene/ethylbenzene mixture to said first portion of hydrocarbon polystyrene non-solvent at the boiling point of said hydrocarbon polystyrene non-solvent and agitating for a time for diffusion of said ethylbenzene from said polystyrene/ethylbenzene mixture into said hydrocarbon polystyrene non-solvent to proceed to a sufficient extent.
 14. The process of claim 13, wherein greater than 90 wt % of said ethylbenzene in said polystyrene/ethylbenzene mixture diffuses into said hydrocarbon polystyrene non-solvent, based on the total weight of said polystyrene/ethylbenzene mixture.
 15. The process of claim 1, wherein the ratio by volume of said first portion of hydrocarbon polystyrene non-solvent to said polystyrene/ethylbenzene mixture is from about 2:1 to about 4:1.
 16. The process of claim 13, wherein said conditions to obtain said washed polystyrene and said second portion of hydrocarbon waste solution comprise adding said second portion of hydrocarbon polystyrene non-solvent to said precipitated polystyrene at the boiling point of said hydrocarbon polystyrene non-solvent and agitating for a time for diffusion of said ethylbenzene from said precipitated polystyrene into said hydrocarbon polystyrene non-solvent to proceed to a sufficient extent.
 17. The process of claim 16, wherein said washed polystyrene comprises less than 0.3 wt % ethylbenzene.
 18. The process of claim 1, wherein said polystyrene waste is post-industrial waste, post-consumer waste or a combination thereof.
 19. The process of claim 1, wherein said dissolving is carried out at a temperature of from about 75° C. to about 85° C.
 20. The process of claim 1, wherein said adding/contacting is carried out at a temperature of from 80° C. to 120° C., 80° C. to 90° C. or about 85° C.
 21. The process of claim 1, wherein the recycled polystyrene has a melt flow index of about 3 g/10 min to about 30 g/10 min.
 22. The process of claim 1, wherein the recycled polystyrene has a melt flow index of about 1 g/10 min to about 15 g/10 min.
 23. The process of claim 5, wherein the recycled polystyrene has a melt flow index of about 3 g/10 min to about 30 g/10 min.
 24. The process of claim 5, wherein the recycled polystyrene has a melt flow index of about 1 g/10 min to about 15 g/10 min. 